Liquid crystal display and method of manufacture

ABSTRACT

An active matrix type liquid crystal display composed of a liquid crystal cell  124  is described. In the liquid crystal cell  124 , liquid crystals at the upper and lower interfaces of a liquid crystal layer  122  inserted between an array substrate  106  having pixel electrodes  128  and an opposed substrate  105  having an opposed electrode  127  have pretilt angles opposite to each other in a positive/negative sense and are aligned in parallel with each other, forming a spray alignment. This liquid crystal display performs displaying by bend-aligning such a liquid crystal cell  124 . The pixel electrodes  128  are formed on a flattening film  100  for covering switching elements  123  or wiring electrodes flat. With this arrangement, a spray to bend alignment transition can be reliably, easily caused in a short time within the liquid crystal cell pixels, so that an OCB mode liquid crystal display free from alignment defects and having high picture quality can be achieved.

This is a Rule 1.53 (b) continuation application of Ser. No. 09/806,230,filed Mar. 28, 2001.

TECHNICAL FIELD

The present invention relates to a high response speed liquid crystaldisplay having a wide viewing angle.

BACKGROUND ART

One known type of liquid crystal displays which have been put topractical use is Twisted Nematic (TN) Mode liquid crystal displays usinga nematic liquid crystal. This mode, however, has drawbacks such as lowresponse speed and narrow viewing angles. Ferroelectric Liquid Crystals(FLC) are known as a display mode having high response speed and wideviewing angles but suffer from serious problems in shock resistance andtemperature characteristics. The Polymer Dispersed Liquid Crystal Mode,which makes use of light scattering, is a rubbingless alignment displaymode, yet it still needs improvements in viewing angles and its responseis not fast enough.

To overcome their drawbacks, there has been proposed the OpticallyCompensated Bend (OCB) Mode as a display mode having fast response andwide viewing angles (Japanese Patent Publication (KOKAI) No. 7-84254(1995)).

FIG. 21 shows a conceptual structural sectional view of the pixel regionof an OCB mode liquid crystal display.

As shown in FIG. 21, this liquid crystal display of the OCB mode hasalignment layers 19 which are oriented in a certain direction; a liquidcrystal cell 14 in which a bend alignment or a bend alignment includinga twisted alignment is generated at the center of the cell 14 by voltageapplication; and a phase compensator 3 for optical phase compensationfor achieving low voltage actuation and enlarged viewing angles.Regarding performance, the OCB mode can provide an active matrix typeliquid crystal display having a wide viewing angle and high responsespeed. In addition, it has the high potential of finding wideapplications as a transmissive or reflective type liquid crystaldisplay.

The above liquid crystal display is formed as follows. The alignmentlayers 19 are attached to the inner surface of an array substrate 6 onwhich switching elements 20 or the like each connected to an pixelelectrode 18 for actuating a pixel region is placed and to the innersurface of an opposed substrate 5 having an posed electrode 17 thereon.These alignment layers 19 have undergone alignment treatment so as to beparallel to each other and have pretilt angles which are about severalto ten degrees, being opposite to each other in a positive/negativesense. A nematic liquid crystal having positive dielectric anisotropy isinserted between the alignment layers 19 to form a liquid crystal layer12. Accordingly, there is formed a spray alignment 11 composed of analignment region in which liquid crystal molecules are diagonally spreadin a vertically symmetrical manner when no voltage is applied.

Then, a voltage higher than the critical transition voltage is appliedacross the above electrodes, whereby transition is caused to form thebend alignment 13 composed of an alignment region in which the liquidcrystal molecules at the center are raised upright or the liquid crystalmolecules including twisted alignment are raised in a twisted manner, asshown in FIG. 21(b) and this region is extended.

At least one polarizer and at least one phase compensator are disposedon the outer sides of the upper and lower substrates, extending in aspecified axial direction. Specifically, there are provided polarizers1, 2 and the phase compensator 3 for optically compensating for the bendalignment cell and lowering voltage in order to attain sufficientcontrast and an increased view angle.

After the transition of the whole pixels, driving signal voltage isvaried to change the degree of the bend alignment state of the liquidcrystal molecules, thereby changing the phase difference to be utilizedfor motion display. Therefore, in the liquid crystal display of the OCBmode, it is necessary to develop transition cores for transition fromthe spray alignment to the bend alignment to bring the pixels into anuniform bend alignment state and to cause such transition throughout theTFT panel pixel region without fail. In reality, it is not easy todevelop transition cores without fail.

When observing the above pixel region with a microscope, it has beenfound that transition cores develop around spacers which are provided soas to scatter for gap formation or that transition cores develop aroundsource lines and gate lines wired along the pixel electrodes, butdeveloping positions are not fixed. In some cases, transition cores arenot developed at all. In this case, the resultant panel has alignmentdefects and visible defects.

As an attempt to promote the above transition, there has been proposed amethod in which a voltage higher than the critical transition voltage isapplied across the opposed electrode and pixel electrodes of the liquidcrystal cell. However, the applied voltage and the time required forvoltage application, which are necessary for the transition, varyconsiderably depending on liquid crystal materials. With some liquidcrystal materials, a time ranging from tens of seconds to severalminutes is required for applying about 20 V across the facing electrodesin order to cause a transition in a TFT liquid crystal panel of the OCBmode. This case is not practical not only in view of the wait time takenfor starting displaying but also in view of the power consumption of theliquid crystal display and the reliability of the driving unit.

In such circumstances, there have been strong demands to a technique forenabling a reliable transition of alignment within all of hundreds ofthousands of pixels in the display panel of an OCB mode liquid crystaldisplay.

Disclosure of the Invention

A series of inventions has been made taking the present status of thetechnology described above into account. The prime object of theinventions is therefore to provide a liquid crystal display which has nodisplay defects and high response speed and is therefore suitable fordisplaying moving pictures and which also has a wide viewing angle,since it can cause alignment transition with substantial reliability andcomplete it in an extremely short time. More particularly, the object ofthe inventions is to provide a bend alignment type liquid crystaldisplay which has high response speed and is therefore suitable fordisplaying moving pictures, since it can cause bend alignment transitionwith substantial reliability and complete it in an extremely short time.

The series of inventions is based on the same or similar concepts, butembodied by different examples. In the present specification, theseinventions are classified according to analogy into a first inventiongroup, a second invention group, a third invention group, a fourthinvention group and a fifth invention group. The contents of each group(i.e., each invention group) will be hereinafter described in order.

First Invention Group

The first invention group is associated with a liquid crystal displaywherein where the alignment state of a liquid crystal to which novoltage is applied is defined as an alignment state 1 and the alignmentstate of the liquid crystal used for performing displaying is defined asan alignment state 2, the alignment state 1 differs from the alignmentstate 2; and wherein for easy, reliable transition from the alignmentstate 1 to the alignment state 2, the unevenness of a surface of asubstrate is flattened and an interface of a liquid crystal layer isflattened.

In liquid crystal displays having a conventional active matrixsubstrate, significant irregularities are usually present on thesubstrates. This is due to the process in which the top layer, that is,an insulating layer having the greatest level difference is removed toexpose the pixel electrodes. Level differences are also caused by sourcewiring and gate wiring positioned around the pixels. Thus, the presenceof level differences is usual for active matrix substrates.

In conventionally used TN type liquid crystal displays, the presence oflevel differences causes alignment disturbance at their positions,resulting in light leakage. To solve this problem, it is necessary toseal the regions where light leakage occurs with a black matrix, whichhowever causes the problem of decreasing brightness. As an attempt toovercome the alignment disturbance and light leakage, there has beenproposed one technique according to which a resin layer is formed on thesubstrate having irregularities thereon and pixel electrodes are thenformed on the resin layer to flatten the device.

In liquid crystal displays in which the alignment state when no voltageis applied differs from the alignment state when displaying can beperformed (e.g., OCB mode liquid crystal displays), “transition”operation is necessary for shifting to the alignment state fordisplaying.

Since OCB mode liquid crystal displays have a parallel alignmentdifferent from that of TN type liquid crystal displays, they do notsuffer from the problem of alignment disturbance such as seen in TN typeliquid crystal displays. However, the inventors have newly found thatlevel differences adversely affect the transition.

In OCB mode liquid crystal displays, transition is carried out byapplying transition voltage. At that time, the bend alignment developsfrom transition cores and this alignment state is expanding. It has,however, been found that the development of the bend alignment ceaseswhen it has reached an irregular region in the substrate andparticularly a region where the substrate is raised and therefore theliquid crystal layer becomes thin. The bend alignment usually developsalong a defect. In a region where the liquid crystal layer is thin, thedefect is intermittent and therefore the development stops. In manycases, such a defect is found in a boundary between two types of sprayalignment states which differ from each other in the tilting directionof the liquid crystal molecules tilted with respect to the direction ofcell thickness.

The inventors have also found that when transition is not completed witha voltage having a specified transition waveform, leaving some pixels inthe spray alignment state, a transition to the bend alignment graduallyoccurs due to normal display driving operation which is performed later.

Based on the above findings, the inventors have accomplished a liquidcrystal display such as OCB mode liquid crystal displays wherein wherethe alignment state of a liquid crystal to which no voltage is appliedis defined as an alignment state 1 and the alignment state of the liquidcrystal used for performing displaying is defined as an alignment state2, the alignment state 1 differs from the alignment state 2; and whereinfor easy, reliable transition, the unevenness of a surface of asubstrate is flattened and an interface of a liquid crystal layer isflattened.

More specifically, a first aspect of the invention is a liquid crystaldisplay having a pair of substrates and a liquid crystal layersandwiched between the pair of substrates, wherein where the alignmentstate of a liquid crystal when no voltage is applied to the liquidcrystal layer is defined as an alignment state 1 and the alignment stateof the liquid crystal used for performing displaying is defined as analignment state 2, the alignment state 1 differs from the alignmentstate 2; and wherein the interface between the liquid crystal layer andat least either one of the pair of substrates is flattened.

With the above arrangement, irregularities in the interface between theliquid crystal layer and the substrate can be reduced so that thetransition from the alignment state 1 to the alignment state 2 can beeasily and reliably carried out.

A second aspect of the invention is a liquid crystal display constructedaccording to the first aspect of the invention, in which either of theabove pair of substrates is an active matrix substrate. According to theabove arrangement, although the active matrix substrate has sourcewiring, gate wiring and the like formed around the pixels and thereforehas great level differences, such a substrate is flattened to have aflat configuration so that the transition from the alignment state 1 tothe alignment state 2 can be easily and reliably carried out.

A third aspect of the invention is a liquid crystal display constructedaccording to the first aspect of the invention, wherein the interface isflattened by a flattening film composed of a resin layer.

A fourth aspect of the invention is a liquid crystal display constructedaccording to the third aspect of the invention, wherein electrodes areformed on at least part of the flattening film.

A fifth aspect of the invention is a liquid crystal display constructedaccording to the first aspect of the invention, wherein the alignmentstate 1 is a spray alignment state and the alignment state 2 is a bendalignment state.

The above arrangements make it possible to provide OCB mode liquidcrystal displays in which easy and reliable transition is enabled.

A sixth aspect of the invention is a liquid crystal display constructedaccording to the first aspect of the invention, wherein the leveldifferences of irregularities on the substrates are 1 μm or less.

A seventh aspect of the invention is a liquid crystal displayconstructed according to the first aspect of the invention, wherein thelevel differences of irregularities on the substrates are 0.5 μm orless.

By limiting the level differences of the irregularities on thesubstrates to 1 μm or less or more preferably to 0.5 μm or less, thetransition from the alignment state 1 to the alignment state 2 can beeasily, reliably performed.

An eighth aspect of the invention is a liquid crystal displayconstructed according to the second aspect of the invention, wherein theactive matrix substrate has a plurality of pixel electrodes and thespacing between the pixel electrodes is within the range of from 1 μm to10 μm.

A ninth aspect of the invention is a liquid crystal display constructedaccording to the second aspect of the invention, wherein the activematrix substrate has a plurality of pixel electrodes and the spacingbetween the pixel electrodes is within the range of from 1 μm to 5 μm.

As described above, the preferred spacing between the pixel electrodesis within the range of from 1 μm to 10 μm or, more preferably, withinthe range of from 1 μm to 5 μm, which makes it easy to reliably carryout the transition from the alignment state 1 to the alignment state 2.

A tenth aspect of the invention is a liquid crystal display constructedaccording to the eighth aspect of the invention, wherein at least partof the pixel electrodes is higher than the average height of the pixelelectrodes. The higher part of the pixel electrodes facilitates thedevelopment of transition cores.

An 11th aspect of the invention is a liquid crystal display constructedaccording to the eighth aspect of the invention, wherein a voltage isapplied across the pixel electrodes and an opposed electrode formed onthe other one of the pair of substrates, thereby transiting thealignment state of the liquid crystal layer to a bend alignment toperform displaying in the condition after the transition.

Second Invention Group

A 12th aspect of the invention is an active matrix type liquid crystaldisplay wherein a liquid crystal layer is sandwiched between an arraysubstrate having pixel electrodes and an opposed substrate having anopposed electrode and the liquid crystal layer is oriented in a bendalignment thereby performing displaying, and wherein conductiveformation members, which are electrically conducted to the opposedelectrode but electrically insulated from the array substrate, areformed on the opposed substrate.

A 13th aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein the conductiveformation members are placed in the space between every adjacent pixelelectrodes so as to be electrically insulated from the array substrate.

With the above arrangements, a diagonal strong electric field isdeveloped and applied across the conductive formation members and thepixel electrodes, causing electric field distortion which brings theliquid crystal molecules in the liquid crystal layer positioned in thevicinity of the conductive formation members and in the vicinity of thepixel electrodes into a b-sprayed alignment state so that the energy ofthe distortion of the liquid crystal molecules becomes greater than thatof their surroundings. In this condition, a high voltage is appliedacross the pixel electrodes and the opposed electrode thereby furtherproviding energy so that transition cores of the bend alignment can bedeveloped and the region of the bend alignment can be extended.

A 14th aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein the pixelelectrodes are positioned on a flattening film formed on the arraysubstrate.

This arrangement further makes it possible to easily and reliably carryout the transition from the spray alignment to the bend alignment.

A 15th aspect of the invention is a liquid crystal display constructedaccording to the 14th aspect of the invention, wherein the leveldifferences of irregularities on the flattening film are 1 μm or less.

A 16th aspect of the invention is a liquid crystal display constructedaccording to the 14th aspect of the invention, wherein the leveldifferences of irregularities on the flattening film are 0.5 μm or less.

By imposing such level difference limitation that the level differencesof irregularities on the substrate are 1 μm or less or more preferably0.5 μm or less, the transition from the spray alignment state to thebend alignment state can be easily, reliably performed.

A 17th aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein the arraysubstrate has a plurality of pixel electrodes and the spacing betweenthe pixel electrodes is within the range of from 1 μm to 10 μm.

An 18th aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein the arraysubstrate has a plurality of pixel electrodes and the spacing betweenthe pixel electrodes is within the range of from 1 μm to 5 μm.

By limiting the spacing between the pixel electrodes to 1 μm to 10 μm ormore preferably 1 μm to 5 μm, the transition from the spray alignment tothe bend alignment can be developed in a better condition.

A 19th aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein the conductiveformation members are covered with an insulating material.

With the above arrangement, the pixel electrodes and the opposedelectrode are electrically insulated from each other since theconductive formation members have an electric insulation relationshipwith the array substrate, so that a liquid crystal display havingexcellent performance can be attained.

A 20th aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein the height of theconductive formation members is smaller than the gap between the arraysubstrate and the opposed substrate

A 21st aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein the conductiveformation members are spacers for maintaining the gap between the arraysubstrate and the opposed substrate to be constant.

The above arrangements actualize a spacer-less process which does notneed provision of ordinary spacers so that the manufacturing process canbe simplified. Further, the arrangements make it possible to achieveuniform displaying so that a liquid crystal display excellent indisplaying performance can be obtained.

A 22nd aspect of the invention is a liquid crystal display constructedaccording to the 12th aspect of the invention, wherein a voltage isapplied across the pixel electrodes and the opposed electrode to transitthe alignment state of the liquid crystal layer to the bend alignment toperform displaying in the condition after the transition.

Third Invention Group

A 23rd aspect of the invention is a liquid crystal display whichcomprises a pair of substrates having electrodes and a liquid crystallayer sandwiched between the pair of substrates; wherein liquid crystalmolecules in the liquid crystal layer are oriented in a bend alignmentto perform displaying; and wherein at least one conductive particlehaving a diameter smaller than the gap between the pair of substrates isplaced on the electrode surface of at least either one of thesubstrates.

A 24th aspect of the invention is a liquid crystal display constructedaccording to the 23rd aspect of the invention, wherein the conductiveparticle is placed on the electrode surface of at least either one ofthe substrates so as to be positioned under an alignment layer.

A 25th aspect of the invention is a liquid crystal display constructedaccording to the 23rd aspect of the invention, wherein the conductiveparticle is placed on the electrode surface of at least either one ofthe substrates so as to be mixed with and dispersed in an alignmentlayer.

With the above arrangements, electrical field concentration occurring inthe conductive particle causes a change in alignment in the neighborhoodof the conductive particle, creating a transition core for a bendalignment with the conductive particle serving as a base point, and thebend alignment region is expanded by high voltage being continuouslyapplied. Thus, the transition can be reliably and readily carried out toobtain an OCB display mode liquid crystal display composed of a liquidcrystal cell free from display defects and having high response speed, awide viewing angle and high picture quality.

A 26th aspect of the invention is a liquid crystal display constructedaccording to the 23rd aspect of the invention, wherein one of the pairof substrates has a pixel electrode and a switching element for everypixel.

A 27th aspect of the invention is a liquid crystal display constructedaccording to the 26th aspect of the invention, wherein the pixelelectrodes are formed on a flattening film for covering the switchingelements or wiring electrodes flat.

This arrangement further facilitates the transition to the bendalignment.

A 28th aspect of the invention is a liquid crystal display constructedaccording to the 23rd aspect of the invention, wherein a voltage isapplied across the electrodes to transit the alignment state of theliquid crystal layer to the bend alignment to perform displaying in thecondition after the transition.

A 29th aspect of the invention is a liquid crystal display constructedaccording to the 23rd aspect of the invention, wherein the conductiveparticle is a resin particle or an inorganic material particle thesurface of which is coated with a conductive thin film.

A 30th aspect of the invention is a liquid crystal display constructedaccording to the 23rd aspect of the invention, wherein the diameter ofthe conductive particle is within the range of from one hundredth thegap between the substrates to one half the gap between the substrates.

The reason why such a limitation is imposed is that if the diameter ofthe conductive particle is smaller than one hundredth the substrate gap,the transition promoting effect decreases and if the diameter of theconductive particle is larger than one half the substrate gap, the pairof substrates are likely to electrically contact with each other.

A 31st aspect of the invention is a method of producing a liquid crystaldisplay which comprises a pair of substrates having electrodes and aliquid crystal layer sandwiched between the pair of substrates andwherein displaying is performed by orienting liquid crystal moleculeswithin the liquid crystal layer in a bend alignment, the methodcomprising:

a dispersion step of dispersedly securing a conductive particle having adiameter smaller than the gap between the substrates to the electrodesurface of at least either one of the substrates; and

an alignment layer formation step of forming an alignment layer byapplying an alignment film material to the electrodes and baking it.

A 32nd aspect of the invention is a method of manufacturing a liquidcrystal display which has a pair of substrates having electrodes and aliquid crystal layer sandwiched between the pair of substrates andwherein displaying is performed by orienting liquid crystal moleculeswithin the liquid crystal layer in a bend alignment, the methodcomprising an alignment layer formation step of disposing a conductiveparticle in a mixed and dispersed manner by applying a material to theelectrode surface of at least one of the substrates and baking it, thematerial containing the conductive particle which has a diameter smallerthan the gap between the substrates and is mixed with and dispersed inthe alignment film material.

These methods obviate the need for a photolitho-process for formingprojections, thereby simplifying the manufacturing method and reducingmanufacturing cost. Further, these methods make it possible to reliably,quickly cause a transition and to obtain an OCB display mode liquidcrystal display composed of a liquid crystal cell free from displaydefects and having high response speed, a wide viewing angle and highpicture quality.

Fourth Invention Group

A 33rd aspect of the invention is a liquid crystal display which has apair of substrates including electrodes and a liquid crystal layersandwiched between the pair of substrates; wherein the liquid crystallayer is oriented in a spray alignment; and wherein the surfaces ofalignment layers formed on the surfaces of the electrodes each have anirregular configuration.

A 34th aspect of the invention is a liquid crystal display constructedaccording to the 33rd aspect of the invention, wherein the irregularconfiguration is a configuration formed by regions changing in thicknessin the alignment layers.

A 35th aspect of the invention is a liquid crystal display constructedaccording to the 33rd aspect of the invention, wherein the alignmentlayers are formed by letterpress printing.

With the above arrangements, the pretilt angle of liquid crystalmolecules within the liquid crystal layer becomes spuriously increasedowing to the alignment layer regions different in thickness, so that ashift to the bend alignment can be quickly carried out during aninitialization process for a spray to bend transition.

A 36th aspect of the invention is a liquid crystal display constructedaccording to the 33rd aspect of the invention, wherein either one of thepair of substrates is an array substrate having pixel electrodes formedthereon, a flattening film is formed on the array substrate, and theflattening film has an irregular configuration.

By virtue of the above arrangement, the liquid crystal molecules withinthe liquid crystal layer are brought into an alignment state in whichthe liquid crystal molecules have various pretilt angles with respect tothe surface of the alignment layer which has an irregular configurationresulting from the provision of the irregular flattening film, so that aquick transition to the bend alignment can be performed during aninitialization process for a spray to bend transition.

A 37th aspect of the invention is a liquid crystal display constructedaccording to the 33rd aspect of the invention, wherein either of thesubstrates is a reflective substrate and the reflecting surface of thissubstrate has an irregular configuration.

By virtue of the above arrangement, the liquid crystal molecules withinthe liquid crystal layer are brought into an alignment state in whichthe liquid crystal molecules have various pretilt angles with respect tothe surface of the alignment layer which has an irregular configurationresulting from the provision of the irregular reflective film, so that aquick transition to the bend alignment can be performed during aninitialization process for a spray to bend transition.

A 38th aspect of the invention is a liquid crystal display constructedaccording to the 33rd aspect of the invention, wherein a voltage isapplied across the electrodes to transit the alignment of the liquidcrystal layer to a bend alignment to perform displaying in the conditionafter the transition.

A 39th aspect of the invention is a method of manufacturing a liquidcrystal display which comprise a pair of substrates having electrodesand a liquid crystal layer sandwiched between the pair of substrates;wherein the liquid crystal layer is oriented in a spray alignment; andwherein the surfaces of alignment layers formed on the surfaces of theelectrodes each have an irregular configuration,

the method comprising the step of forming the irregular configurationsof the electrode surfaces by use of a UV asher, ozone asher, UV/ozoneasher or the like.

A 40th aspect of the invention is a method of manufacturing a liquidcrystal display which has a pair of substrates having electrodes and aliquid crystal layer sandwiched between the pair of substrates; whereinthe liquid crystal layer is oriented in a spray alignment; and whereinthe surfaces of alignment layers formed on the surfaces of theelectrodes each have an irregular configuration, the method comprising:a dispersion step of dispersing, beforehand, powder or minute particlesinto printing varnish used for forming the alignment layers on thesurfaces of the electrodes; and an alignment layer formation step offorming the alignment layers by applying the varnish onto the surfacesof the electrodes and baking the varnish.

These methods obviate the need for a photolitho-process for formingprojections, thereby simplifying the manufacturing method and reducingmanufacturing cost. In addition, the liquid crystal molecules within theliquid crystal layer are consequently brought into an alignment statehaving various liquid crystal directors, but they are basically in astate having surface alignment directors perpendicular to thesubstrates. As a result, a liquid crystal display can be obtained inwhich a shift to the bend alignment can be quickly performed with theportions having directors perpendicular to the substrates as cores,during an initialization process for a spray to bend transition.

Fifth Invention Group

A 41st aspect of the invention is a liquid crystal display whichcomprises a pair of substrates having electrodes and a spray-alignedliquid crystal layer sandwiched between the pair of substrates; whereina plurality of spacers are placed between the pair of substrates;wherein the spacers are securely attached to at least either one of thesubstrates with an adhesive which increases the pretilt angle of liquidcrystal molecules within the liquid crystal layer; and wherein theadhesive is spread over the substrate.

A 42nd aspect of the invention is a liquid crystal display constructedaccording to the 41st aspect of the invention, wherein the adhesive isspread over a distance approximately no less than the diameter of eachspacer, being centered on the spacer.

A 43rd aspect of the invention is a liquid crystal display constructedaccording to the 41st aspect of the invention, wherein the adhesive isspread, in one direction from each spacer, over a distance approximatelyno less than the radius of the spacer, being centered on the spacer.

With the above arrangements, the liquid crystal molecules located ateach spacer are oriented in a one-side HAN alignment or HAN alignment,the one-side HAN alignment being such that the pretilt angle isspuriously increased by regions where said at least one of the pair ofsubstrates differ from the other substrate. Therefore, a shift to thebend alignment can be quickly performed during an initialization processfor a spray to bend transition.

A 44th aspect of the invention is a liquid crystal display constructedaccording to the 41st aspect of the invention, wherein the adhesivecontains, as a component, a fluorine type alignment material, a fluorinetype material or a long-chain alkyl material.

A 45th aspect of the invention is a liquid crystal display constructedaccording to the 41st aspect of the invention, wherein a voltage isapplied across the electrodes to cause a transition of the liquidcrystal layer from a spray alignment to a bend alignment, therebyperforming displaying.

A 46th aspect of the invention is a method of manufacturing a liquidcrystal display which comprises a pair of substrates having electrodesand a spray-aligned liquid crystal layer sandwiched between the pair ofsubstrates, the method comprising: a spacer scattering step ofscattering spacers onto at least either one of the pair of substrates,the spacers having an adhesive adhered thereto which increases thepretilt angle of liquid crystal molecules within the liquid crystallayer; a substrate stationary placement step of placing the substrate soas to be stationary over which the adhesive is allowed to spread; and aliquid crystal cell formation step of forming a liquid crystal cell bysticking the pair of substrates together.

A 47th aspect of the invention is a liquid crystal display manufacturingmethod according to the 46th aspect of the invention, wherein in thesubstrate stationary placement step, the substrate is horizontallyplaced so as to be stationary and the adhesive is spread over a distanceapproximately no less than the diameter of each spacer, being centeredon the spacer.

A 48th aspect of the invention is a liquid crystal display manufacturingmethod according to the 46th aspect of the invention, wherein, in thesubstrate stationary placement step, the substrate is vertically placedso as to be stationary and the adhesive is spread, in one direction fromeach spacer, over a distance approximately no less than the radius ofthe spacer, being centered on the spacer.

With the above methods, the liquid crystal molecules located at eachspacer are oriented in a one-side HAN alignment in which the pretiltangle is spuriously increased by regions in at least one of the pair ofsubstrates which differ from their corresponding regions in the othersubstrate. This enables an OCB type liquid crystal display in which ashift to the bend alignment can be quickly performed during aninitialization process for a spray to bend transition.

A 49th aspect of the invention is a method of manufacturing a liquidcrystal display which comprises a pair of substrates having electrodesand a spray-aligned liquid crystal layer sandwiched between the pair ofsubstrates, the method comprising: a spacer scattering step ofscattering spacers onto at least either one of the pair of substrates,the spacers having an adhesive adhered thereto which increases thepretilt angle of liquid crystal molecules within the liquid crystallayer; and a substrate stationary placement step of sticking the pair ofsubstrates together on which the adhesive is allowed to spread.

With the above method, the liquid crystal molecules located at eachspacer are oriented in a HAN alignment in which the pretilt angle isspuriously increased, so that an OCB type liquid crystal display can beobtained in which a shift to the bend alignment is quickly performedduring an initialization process for a spray to bend transition.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is conceptual structural views of a liquid crystal displayaccording to an embodiment 1 of the invention.

FIG. 2 is schematic views of a liquid crystal display when a transitiontest is conducted with projections formed on a flattening film.

FIG. 3 is a schematic view showing pixel electrodes each of which has anend higher than the average height of the pixel electrode.

FIG. 4 is conceptual structural views of a liquid crystal displayaccording to an embodiment 2 of the invention.

FIG. 5 is conceptual structural views of another liquid crystal displayaccording to the embodiment 2 of the invention.

FIG. 6 is conceptual structural views of still another liquid crystaldisplay according to the embodiment 2 of the invention.

FIG. 7 is conceptual structural views of a liquid crystal displayaccording to an embodiment 3-1 of the invention.

FIG. 8 is conceptual views of a method of manufacturing the liquidcrystal display according to the embodiment 3-of the invention.

FIG. 9 is conceptual structural views of a liquid crystal displayaccording to an embodiment 3-2 of the invention.

FIG. 10 is conceptual views of a method of manufacturing the liquidcrystal display according to the embodiment 3-2 of the invention.

FIG. 11 is a conceptual structural view of a liquid crystal display inwhich a zinc oxide is used as a conductive particle.

FIG. 12 is conceptual views depicted for explaining the movement ofliquid crystal directors when transited from a spray alignment to a bendalignment in an OCB mode type liquid crystal display.

FIG. 13 conceptually shows the sectional structure of a test cell usedin a liquid crystal display according to an embodiment 4-1 of theinvention.

FIG. 14 conceptually shows the sectional structure of a test cell usedin a liquid crystal display according to an embodiment 4-2 of theinvention.

FIG. 15 conceptually shows the sectional structure of a test cell usedin a liquid crystal display according to an embodiment 4-3 of theinvention.

FIG. 16 conceptually shows the sectional structure of a test cell usedin a liquid crystal display according to an embodiment 4-5 of theinvention and shows a spray alignment state around a spacer.

FIG. 17 conceptually shows the sectional structure of a test cell usedin a liquid crystal display according to an embodiment 5-1 of theinvention.

FIG. 18 is a conceptual view showing a rubbing direction of the liquidcrystal display shown in FIG. 17.

FIG. 19 conceptually shows the sectional structure of a test cell usedin a liquid crystal display according to an embodiment 5-2 of theinvention.

FIG. 20 conceptually shows the sectional structure of a test cell usedin a liquid crystal display according to an embodiment 5-3 of theinvention.

FIG. 21 is a conceptual structural view of a conventional liquid crystaldisplay.

BEST MODE FOR CARRYING OUT THE INVENTION

(1) An Embodiment of the First Invention Group

Referring now to the drawings, the first invention group of the presentinvention will be described below.

Embodiment 1

FIG. 1 shows conceptual structural views of a liquid crystal displayconstructed according to an embodiment 1 of the invention. Specifically,FIG. 1(a) is a conceptual structural sectional view showing the liquidcrystal display on the basis of pixel unit; FIG. 1(b) is a conceptualstructural plan view similarly showing the liquid crystal display on thebasis of pixel unit; and FIG. 1(c) diagrammatically shows a bendalignment state and aligning direction of liquid crystal molecules asviewed from their sides.

The liquid crystal display of this embodiment has an active matrix typeliquid crystal cell 124 at either or both sides of which two polarizersand a phase compensator for optical compensation (not shown) areprovided.

The liquid crystal cell 124 has an opposed substrate 105 and an arraysubstrate 106 which face each other. Arranged on the array substrate 106are switching elements 123 made of TFT, source wiring electrodes 181 andothers. The switching elements 123 and the source wiring electrodes 181etc. are laminated with a flattening film 100 having a thickness ofabout 3 μm and made of a transparent insulating film material such astransparent acrylic organic polymers.

A pixel electrode 128 made of ITO is formed for every pixel unit so thata plurality of pixel electrodes 128 are spaced at intervals of about 3μm on the flattening film 100. The drain electrode of each switchingelement 123 is conducted to its corresponding pixel electrode 128through a conducting inlet 110 formed on the flattening film 100.

An opposed electrode 127 is formed on the opposed substrate 105. Formedon the surfaces of the opposed electrode 127 and the pixel electrodes128 are alignment layers 129 and 191, respectively, which are made byapplying and baking, for example, a polyamic acid type polyimidealignment film material produced by Nissan Chemical Industries, Ltd.

Interposed between the alignment layers 129 and 191 are spacers (notshown) having a diameter of about 5 μm for keeping a constant spacingbetween the array substrate 106 and the opposed substrate 105 and aliquid crystal layer 122 made of a nematic liquid crystal materialhaving positive dielectric anisotropy.

The alignment layers 129, 191 are treated in the same direction (i.e.,in the direction of the source wiring electrodes 181 as indicated byarrow in FIG. 1(b)) so as to be substantially parallel with each other,such that the pretilt angles of the liquid crystal molecules on theirsurfaces are about 5 to 6 degrees, being opposite to each other in apositive/negative sense.

Although not shown in the drawings, such treatment creates the liquidcrystal cell 124 of the so-called spray alignment in which liquidcrystal molecules within the liquid crystal layer 122 are diagonallyspread when the liquid crystal layer 122 is in the so-called non-voltageapplied condition.

In the liquid crystal display of the above structure, prior to normaldisplaying, gate wiring electrodes 126 are brought into a normalscanning condition or almost all of them are turned on and a pulsehaving a high voltage of −15 V for instance is repeatedly applied acrossthe opposed electrode 127 and the pixel electrodes 128.

With the flattening effect of the flattening film 100, the pixelelectrodes 128 can be formed at extremely narrow intervals, and electricfield distortion is developed and applied across the pixel electrodes128, or alternatively, electric field distortion is developed betweenthe pixel electrodes 128 and the gate wiring electrodes 126. This causesa shift from the spray alignment (not shown) to a b-spray alignment 112at the side portions of the source wiring electrodes or gate wiringelectrodes of the pixel electrodes 128 within the pixel region and fromthis, transition cores of a bend alignment 113 are generated and thebend alignment regions expand.

Finally, the regions of a t-spray alignment 111 are all transited to thebend alignment 113, and accordingly, the pixel region is entirelychanged to the bend alignment region in about 0.5 sec.

The transition of the entire TFT panel can be readily completed in about3 sec. Thus, an OCB display mode liquid crystal display can be achieved,which is composed of an active matrix type liquid crystal cell free fromdisplaying defects and capable of causing a reliable, quick transitionand which ensures high response speed, a wide view angle and highpicture quality.

The electric field distortion occurring in the narrow space between theadjacent pixel electrodes permits the liquid crystal molecules in thevicinity of the side portions of the pixel electrodes to be aligned in ahorizontal condition on the surface of the substrate, causing theso-called b-spray alignment 112 so that their energy of distortionbecomes higher than the surroundings. In this condition, high voltage isapplied across the upper and lower electrodes, thereby further impartingenergy, so that transition cores develop beside the pixel electrodes andthe regions of the bend alignment 113 are expanding.

In addition, by reducing the irregularities of the surfaces of the pixelelectrodes 128 themselves or irregularities throughout the pixelelectrode region by use of the flattening film 100, the transition fromthe spray alignment to the bend alignment can be easily and reliablycarried out.

Herein, the experiment shown in FIG. 2 was conducted. FIG. 2 is aschematic view when a transition test was conducted with projectionsformed on the flattening film. Specifically, FIG. 2(a) is a conceptualstructural sectional view showing a liquid crystal display on the basisof pixel unit and FIG. 2(b) is a conceptual structural plan viewsimilarly showing the liquid crystal display on the basis of pixel unit.

As shown in FIG. 2(a), projections 100 a, 100 b, 100 c, 100 d wereformed on the flattening film 100 and the relationship between theflatness of the flattening film and the transition from the sprayalignment to the bend alignment was checked in the experiment. It shouldbe noted that the heights of the projections 100 a, 100 b, 100 c and 100d are 1 μm, 0.5 μm, 0.5 μm, and 2 μm, respectively.

In the liquid crystal display having such a structure, prior to normaldisplaying, the gate wiring electrodes 126 were brought into a normalscanning condition or almost all of them were turned on, and then apulse having a high voltage of −15V for instance was repeatedly appliedacross the opposed electrode 127 and the pixel electrodes 128, in thesame way as described earlier. Thus, regions of the bend alignment 113were expanded within the pixel region.

As a result, it was observed that the regions of the bend alignment 113which had developed in the side portions of the source wiring electrodesor gate wiring electrodes of the pixel electrodes 128 could expand,overriding the projections 100 a, to 100 c, but could not expand,overriding the projection 100 d so that the bend alignment regionsstopped at the projection 100 d. It is understood from the result ofthis experiment that perfect flattening by the flattening film 100 isnot required, and practically, the level difference of the flatteningfilm 100 may be 1 μm or less and more preferably 0.5 μm or less.

By flattening the substrate with the flattening film, the spacingbetween adjacent pixel electrodes can be shortened. In a known ordinaryconfiguration, the spacing between adjacent pixel electrodes is as longas about 20 μm, because a sufficient fitting margin is necessary betweenpixel electrodes and a source electrode. On the other hand, in theinvention, the spacing between the pixel electrodes can be set takinginto account only the fitting margin for a pixel electrode to a pixelelectrode, so that the spacing can be reduced to 10 μm or less which isno more than one half the known case. By thus shortening the spacingbetween the pixel electrodes, the transition proceeds between the pixelelectrodes more smoothly, expanding across the space between the pixels.This spacing is preferably within the range of 1 μm to 10 μm and morepreferably within the range of 1 μm to 5 μm.

The configuration shown in FIG. 3 may be employed. Specifically, aconductive projection 128 a made of a resin or the like covered with ITOis formed on each pixel electrode 128, particularly, at one end thereof,whereby the development of transition cores in the neighborhood of theprojections 128 a can be further promoted.

As far as the space between the transitions cores is flat, or as far asthe areas toward which the transition cores expand are flat, the bendregions can easily expand.

As described earlier, by reducing irregularities and shortening thespacing between every adjacent pixel electrodes, the transition can beeasily, reliably carried out throughout the liquid crystal cell.

(2) An Embodiment of the Second Invention Group

Reference is made to the drawings to hereinafter describe the secondinvention group of the invention.

Embodiment 2

FIG. 4 is conceptual structural views of a liquid crystal displayconstructed according to Embodiment 2 of the invention. Specifically,FIG. 4(a) is a conceptual structural sectional view showing the liquidcrystal display on the basis of pixel unit, whereas FIG. 4(b) is aconceptual structural plan view similarly showing the liquid crystaldisplay on the basis of pixel unit.

As shown in FIG. 4(a), the liquid crystal display of Embodiment 2 of theinvention has an active matrix type liquid crystal cell 134 having, ateither or both sides thereof, two polarizers and a phase compensator foroptical compensation (not shown).

The liquid crystal cell 134 has the opposed substrate 105 and the arraysubstrate 106 on which switching elements 133 made of TFT, the sourcewiring electrodes 181 and others are disposed. Laminated to the tops ofthe switching elements 133, the wiring electrodes 181 and others is theflattening film 100 made of a transparent insulating film material suchas transparent acrylic organic polymers and having a thickness of about3 μm.

A pixel electrode 138 made of ITO is formed for every pixel so that aplurality of pixel electrodes 138 are spaced at intervals of about 8 μmon the flattening film 100. The drain electrode of each switchingelement 133 is conducted to its corresponding pixel electrode 138through the conducting inlet 110 formed on the flattening film 100.

The opposed electrode 127 made of ITO is formed on the opposed substrate105. 7 μm-wide, column-like conductive formation members 141electrically conducted to the opposed electrode 127 are positioned abovethe respective spaces between the adjacent pixel electrodes 138. It isalso possible to place the conductive formation members 141 in theregion of the pixel electrodes 138 (i.e., the areas above the pixelelectrodes 138).

The length of the column-like conductive formation members 141 is about3 μm which is shorter than the diameter (5 μm) of spacers provided forkeeping the gap between the substrates 105 and 106 constant. Theconductive formation members 141 are formed so as to be electricallyinsulated from the array substrate 106. That is, the conductiveformation members 141 are positioned above the spaces between the pixelelectrodes 138, but have a non-contact, electric insulation relationshipwith the array substrate 106.

To further improve the electric insulation of the conductive formationmembers 141, at least the leading ends of the conductive formationmembers 141 may be covered with an electric insulating material such asSiO₂ and SiNx. Of course, the conductive formation members 141 may beentirely covered with an electric insulating material. The conductiveformation members 141 themselves can be formed, for instance, throughthe process for forming the color filter, ITO and others whichconstitute the opposed electrode.

A polyimide alignment film material of a polyamic acid type produced,for example, by Nissan Chemical Industries, Ltd. is applied to thesurfaces of the opposed electrode 127, the conductive formation members141 and the pixel electrodes 138 thus prepared and then baked, therebyforming the alignment layers 129, 191.

The alignment layers 129, 191 are treated so as to be aligned in thesame direction (i.e., in the direction of the source wiring electrodes181 as indicated by arrow in FIG. 4(b)) in substantially parallel witheach other, such that the pretilt angles of the liquid crystal moleculeson the surfaces of the alignment layers 129, 191 are about 5 to 6degrees, being opposite to each other in a positive/negative sense.

A liquid crystal layer 122 made of a nematic liquid crystal materialhaving positive dielectric anisotropy is inserted between the substrate105 and 106.

In this way, a spray alignment type liquid crystal cell 134 is formed,in which the liquid crystal layer 132 is composed of an alignment regionin which the liquid crystal molecules are diagonally spread when theliquid crystal layer 132 is in the so-called no voltage appliedcondition.

In the above liquid crystal display, prior to normal displaying, thegate wiring electrodes 136 are brought into a normal scanning conditionor almost all of them are turned on, and then a pulse having a highvoltage of −15V for instance is repeatedly applied across the opposedelectrode 127 and the pixel electrodes 138. At that time, a diagonalstrong electric field is developed and applied across the conductiveformation members 141 electrically connected to the opposed electrode127 and the aide portions of the pixel electrodes 138 which are in closeproximity to the conductive formation members 141. This cause analignment change such that, the spray alignment within the pixel regionis changed to the b-spray alignment 112 at the side portions of thepixel electrodes 138 close to the conductive formation members 141.Then, the transition cores of the bend alignment 113 develop and theregions of the bend alignment 113 expand.

Although not shown in the drawings, all the t-spray alignment regionswhich have been formed are finally changed to the bend alignment 113.The pixel region can be entirely changed to the bend alignment in about0.2 sec., and the transition of the whole TFT panel can be quicklycompleted in about 1 sec. Thus, an OCB display mode liquid crystaldisplay is obtained, which is composed of an active matrix type liquidcrystal cell enabling a reliable, quick transition and free from displaydefects and which has high response speed, a wide viewing angle and highpicture quality.

This is conceivably attributable to the following fact: a diagonalelectric field is developed and applied across the conductive formationmembers 141 and the edges of the pixel electrodes 138 which are in closeproximity to the conductive formation members 141, giving rise to anelectric field distortion which causes the liquid crystal molecules nearthe distortion to be aligned in a horizontal condition on the substratesurface (this is the so-called b-spray alignment 112), so that theenergy of distortion of the liquid crystal molecules becomes higher thanthe surroundings. In this condition, high voltage is applied across theupper and lower electrodes, whereby energy is further imparted,developing the transition cores of the bend alignment at the edges ofthe pixel electrodes and then the regions of the bend alignment 113 areexpanding.

As shown in FIG. 5, the width of the conductive formation members 141may be larger than the spacing W1 between the pixel electrodes andtherefore the conductive formation members 141 may partly ride on thepixel electrodes 128. Although not shown in the drawings, the conductiveformation members 141 may be much smaller.

In view of the aperture ratio of the pixels, the spacing between thepixel electrodes may be 10 μm or less and more preferably within therange of from 1 μm to 5 μm.

The conductive formation members 141 are not limited to particularshapes but may be in the form of a column or trapezoid. Additionally,although the conductive formation members 141 are positioned above thesource wiring electrodes 181, it is obvious that the conductiveformation members 141 may be positioned above the gate wiring electrodes126.

While the conductive formation members 141 have length shorter than thediameter of the spacers (not shown) provided for keeping the gap betweenthe substrates 105 and 106 constant in the present embodiment, they mayserve by themselves as spacers for constantly keeping the gap betweenthe substrates 105 and 106 which face each other, as shown in FIG. 6.

In other words, the conductive formation members 142 are formed so as tohave approximately the same length as ordinary spacers for keeping thegap between the substrates 105 and 106 constant.

In this case, since the conductive formation members 142 are positionedbetween the pixel electrodes 138, it is necessary for keeping electricalinsulation to set the width of the conductive formation members 142 tobe narrower than the spacing W2 between the pixel electrodes. But,provided that at least the leading ends of the spacer conductiveformation members 142 are covered with an electrically insulatingmaterial at their leading ends, the width of the conductive formationmembers 142 may be larger than the spacing W2 between the pixelelectrodes. The shape of the conductive formation members 142 is notparticularly limited.

The liquid crystal display thus prepared does not need ordinary spacersand therefore it can be manufactured by a spacerless process, whichcontributes to simplification of the manufacturing process. Further, byvirtue of the spacerless process, the liquid crystal display can performmore uniform displaying.

Accordingly, an OCB display mode liquid crystal display can be achieved,which is composed of a liquid crystal cell capable of causing areliable, quick transition and free from display defects and whichensures high response speed, a wide view angle and high picture quality.

In the present embodiment, the pixel electrodes are formed on theflattening film which covers the switching elements and the wiringelectrodes, and the conductive formation members conducted to theopposed electrode are each positioned between every adjacent pixelelectrodes. The same transition facilitating effect can be achieved byan alternative arrangement in which ordinary pixel electrodes aredisposed on the array substrate 106 without the flattening film and theconductive formation members conducted to the opposed electrode arerespectively positioned at the spaces between the adjacent pixelelectrodes.

Further, in another alternative liquid crystal display, the substratesmay be formed from plastics, or either of the substrates may be formedfrom a reflective material or silicon.

Other Features Associated with the First and Second Invention Groups

(1) The material of the flattening film may be a transparent inorganicthin film material such as silica. (2) The alignment layers may beformed from any materials as far as the specified pretilt angle can beobtained. Examples of the material of the alignment layers includepolyimide materials. The alignment treatment may be done by anon-rubbing alignment treatment technique such as optical alignment.

(3) While the alignment treatment is done in a direction parallel to thesource wiring electrodes in the above description, it may be done in adirection parallel to the gate wiring electrodes. Further, it may bedone in a direction diagonal to the wiring electrode lines. Thedirection of the alignment treatment can be arbitrarily selectedaccording to optical viewing angle characteristics.

(4) The liquid crystal display to which the invention is applied is notlimited to the OCB mode but may be of any other modes in whichspeeding-up of the phase transition of the liquid crystal layer isrequired.

(3) Embodiments of the Third Invention Group

Referring to the drawings, the third invention group of the inventionwill be described below.

Embodiment 3-1

FIG. 7 shows conceptual structural views of a liquid crystal displayconstructed according to an embodiment 3-1 of the invention. As shown inFIG. 7(a), the liquid crystal display of this embodiment is composed ofa liquid crystal cell 224 at either or both sides of which there areprovided two polarizers and a phase compensator for optical compensation(not shown).

The liquid crystal cell 224 has substrates 205, 206 which face eachother. Disposed on the substrate 205 is an opposed electrode 217.Disposed on the substrate 206 is pixel electrodes 271. On the electrodes217, 271, a plurality of conductive particles 280 (at least oneconductive particle is needed) are dispersedly placed, the particlesbeing made of polymer resin particles the surfaces of which are coatedwith an Au thin film having a diameter of approximately 1.5 μm.

Alignment layers 290, 291 are so formed as to cover the surface of theopposed electrode 217 and the surface of the pixel electrodes 271 andthe conductive particles 280.

Inserted between the alignment layers 290, 291 are spacers (not shown)which have a diameter of about 5 μm for keeping the gap between thesubstrates constant and a liquid crystal layer 222 made of a nematicliquid crystal material having positive dielectric anisotropy.

The alignment layers 290, 291 are treated so as to be aligned in thesame direction (i.e., in the lateral direction on the plane of thedrawing) in substantially parallel with each other, such that the liquidcrystal layer 222 forms the so-called spray alignment composed of analignment region in which the liquid crystal molecules are diagonallyspread when the liquid crystal layer 222 is in the so-called no voltageapplied condition and such that the pretilt angles of the liquid crystalmolecules on the surfaces of the alignment layers 290, 291 are about 5to 6 degrees, being opposite to each other in a positive/negative sense.

Since the area occupied by the conductive particles 280 is much smallerthan the area of the alignment layers 290, 291, the alignment of thewhole liquid crystal layer is virtually unaffected. Therefore, there isformed the liquid crystal cell 224 of the so-called spray alignment 221composed of an alignment region where the liquid the crystal moleculesin the liquid crystal layer 222 are diagonally spread when the liquidcrystal layer 222 is in the so-called no voltage applied condition.

Next, a method of manufacturing the above liquid crystal display will bedescribed.

FIG. 8 is a conceptual view illustrating a method of manufacturing theliquid crystal display of the embodiment 2-1.

First of all, the pixel electrodes 271 are formed on the substrate 206.

As shown in FIG. 8(a), the conductive particles 280 are then dispersedsuch that a plurality of conductive particles 280 (at least oneconductive particle is necessary for each pixel) are placed on the pixelelectrodes 271 for every pixel by use of air or an inert gas, theconductive particles 280 being made of polymer resin particles whosesurfaces are coated with an Au thin film having a diameter of about 1.5μm, and the surfaces of the conductive particles 280 having athermoplastic or thermosetting adhesive applied thereto.

Thereafter, heat is applied to the substrate 206 to securely adhere theconductive particles 280 to the pixel electrodes 271.

As shown in FIG. 8(b), a polyamic acid type polyimide alignment filmmaterial varnish, for example, produced by Nissan Chemical Industries,Ltd. is applied by a spinner or a printer to cover the surfaces of thepixel electrodes 271 and the conductive particles 280. Then, baking iscarried out to form the alignment layer 291.

Although not shown in the drawings, the same process is performed todisperse the conductive particles 280 and form the alignment layer 290on the substrate 205.

Then, the alignment layers 290, 291 are treated so as to be aligned inthe same direction in substantially parallel with each other, such thatthe liquid crystal layer forms the so-called spray alignment composed ofan alignment region in which the liquid crystal molecules are diagonallyspread when the liquid crystal layer is in the so-called no voltageapplied condition and such that the pretilt angles of the liquid crystalmolecules on the surfaces of the alignment layers 290, 291 are about 5to 6 degrees, being opposite to each other in a positive/negative sense.

For keeping the gap between the substrates 205, 206 constant, thespacers having a diameter of about 5 μm and the liquid crystal layermade of a nematic liquid crystal material having positive dielectricanisotropy are inserted between the substrates 205, 206.

Next, the operation of the liquid crystal display thus formed will bedescribed.

Reference is now made to the conceptual structural sectional view ofFIG. 7(b) which illustrates the liquid crystal display on the basis ofpixel unit. Prior to normal displaying, pulses having for example highvoltages of ±15V were repeatedly applied across the opposed electrode217 and the pixel electrodes 271 continuously or intermittently atintervals of several tens of ms to hundreds of ms. This caused electricfield concentration at the conductive particles 280 placed on theopposed electrode 217 and on the pixel electrodes 271. Then, analignment change occurred in the neighborhood of the conductiveparticles 280 from the spray alignment (now shown) within the pixelregion, and transition cores of the bend alignment 213 developed withthe conductive particles 280 serving as base points. The subsequentapplication of high voltage made the bend alignment regions expand.

The pixel region could be entirely shifted to the bend alignment regionin about 0.5 sec. and the transition of the whole panel could be quicklycompleted in about 2 sec. After the completion of the transition, theliquid crystal display was connected to an ordinary display drivingcircuit. Thus, an OCB display mode liquid crystal display could beobtained, which was composed of a liquid crystal cell capable ofperforming reliable, quick transition and free from display defects andwhich had high response speed, a wide viewing angle and high picturequality.

Although the conductive particles 280 are securely attached to both ofthe substrates 205, 206 which face each other in the present embodiment,the conductive particles 280 may be securely attached to either one ofthe substrates.

Embodiment 3-2

FIG. 9 shows a conceptual structural view of a liquid crystal displayconstructed according to an embodiment 3-2 of the invention.

As shown in FIG. 9(a), the liquid crystal display comprises an activematrix type liquid crystal cell 234 at either or both sides of which twopolarizers and a phase compensator for optical compensation (these arenot shown) are disposed.

The liquid crystal cell 234 has an opposed substrate 205 and an arraysubstrate 206 which face each other. On the array substrate 206, aswitching element 243 made of TFT, a gate wiring electrode and a sourcewiring electrode (not shown) are disposed for every pixel. Connected toeach switching element 243 is the pixel electrode 271 made of ITO. Anopposed electrode 217 made of ITO is formed on the opposed substrate205.

Formed on the surfaces of the opposed and pixel electrodes 217, 271 arealignment layers 290, 291 in which the conductive particles 280 aremixed and dispersed. The conductive particles 280 are made of polymerresin particles which have a diameter of about 1.5 μm and whose surfacesare coated with an Au thin film.

Most of the conductive particles 280 are in electrical contact with theelectrodes 217, 271. Although the conductive particles 280 are dispersedon both of the substrates 205, 206 in this embodiment, the conductiveparticles 280 may be dispersed in either one of the substrates.

The alignment layers 290, 291 are treated so as to be aligned in thesame direction in substantially parallel with each other, such that thepretilt angles of the liquid crystal molecules on their surfaces areabout 5 to 6 degrees, being opposite to each other in apositive/negative sense.

The liquid crystal layer 222 made of a nematic liquid crystal materialhaving positive dielectric anisotropy is inserted between the opposedsubstrate 205 and the array substrate 206. There is formed the liquidcrystal cell 234 of the so-called spray alignment 221 composed of analignment region in which the liquid crystal molecules in the liquidcrystal layer 222 are diagonally spread when the liquid crystal layer222 is in the so-called no voltage applied condition.

Next, there will be explained a method of manufacturing the above liquidcrystal display.

FIG. 10 is a conceptual view illustrating a method of manufacturing theliquid crystal display of the embodiment 3-2.

As shown in FIG. 10(a), wiring electrodes (not shown), the switchingelements 243, and the pixel electrodes 271 are formed on the arraysubstrate 206.

Then, the conductive particles 280 made of Au spherical particles havinga diameter of e.g., about 1.5 μm which is smaller than the gap betweenthe substrates and a polyamic acid type polyimide alignment filmmaterial varnish produced by e.g., Nissan Chemical Industries, Ltd. aremixed and dispersed.

As shown in FIG. 10(b), the material prepared by mixing the alignmentfilm material with the conductive particles such that the particles aredispersed therein is applied onto the surfaces of the pixel electrodes271 of the substrate 206 by means of a spinner or a printer and then,baking is carried out to form the alignment layer 291 containing theconductive particles 280 dispersed therein.

Although not shown in the drawings, the conductive particles 280 aredispersed and the alignment layer 290 is formed on the substrate 205 inthe same way.

The alignment layers 290, 291 are treated so as to be aligned in thesame direction in substantially parallel with each other, such that theliquid crystal layer forms the so-called spray alignment composed of analignment region in which the liquid crystal molecules are diagonallyspread when the liquid crystal layer is in the so-called no voltageapplied condition and such that the pretilt angles of the liquid crystalmolecules on their surfaces are about 5 to 6 degrees, being opposite toeach other in a positive/negative sense.

Although not shown in the drawings, spacers having a diameter of about 5μm for keeping the gap between the substrates constant and the liquidcrystal layer made of a nematic liquid crystal material having positivedielectric anisotropy are inserted between the substrates.

Since the area occupied by the conductive particles is much smaller thanthe area of the alignment layers, the alignment of the whole liquidcrystal layer is virtually unaffected. Therefore, there is formed theliquid crystal cell of the so-called spray alignment composed of analignment region where the liquid crystal molecules in the liquidcrystal layer are diagonally spread when the liquid crystal layer is inthe so-called no voltage applied condition.

Next, the operation of the liquid crystal display thus formed will bedescribed.

Reference is now made to the conceptual structural sectional view ofFIG. 9(b) which illustrates the active matrix type liquid crystaldisplay on the basis of pixel unit. Prior to normal displaying, the gateelectrodes were brought into a normal scanning condition or almost allof the gate electrodes were turned on. In this condition, a pulse havinga high voltage of e.g., −15V was repeatedly applied across the opposedelectrode 217 and the pixel electrodes 271 continuously orintermittently at intervals of several tens of ms to hundreds of ms.This may be carried out by applying −15V pulses based on the voltageapplied to the opposed electrode. Alternatively, bias voltage may besuperimposed to the above pulse voltage.

The above voltage application caused electric field concentration aroundthe conductive particles 280 in contact with the electrodes 217, 271.Then, an alignment change occurred in the neighborhood of the conductiveparticles 280 from the spray alignment (now shown) within the pixelregion, and from this, transition cores of the bend alignment 213developed. The subsequent application of high voltage allowed the bendalignment regions to expand. The pixel region could be entirely shiftedto the bend alignment region in about 0.5 sec. and the transition of thewhole panel could be quickly completed in about 1 sec.

After the completion of the transition, the liquid crystal display wasswitched to an ordinary display driving circuit. Thus, an OCB displaymode liquid crystal display of the active matrix type could be obtained,which was composed of a liquid crystal cell capable of performingreliable, quick transition and free from display defects and which hadhigh response speed, a wide viewing angle and high picture quality.

This is conceivably attributable to the following fact: An extremelystrong electric field concentration occurred between the conductiveparticles and the opposed electrode, causing electric field distortionso that the liquid crystal molecules of the spray alignment in theneighborhood had higher energy of distortion than the surroundings. Byvirtue of the high voltage continuously applied across the upper andlower electrodes in this condition, energy was further imparted so thattransition cores of the bend alignment 213 were generated with theconductive particles 280 serving as base points and the bend alignmentregions expanded.

In this way, an OCB display mode liquid crystal display can be achieved,which is composed of an active matrix type liquid crystal cell capableof quickly, reliably transiting from the spray alignment to the bendalignment in the entire liquid crystal layer positioned between thefacing substrates and free from display defects and which ensures highresponse speed, a wide viewing angle and high picture quality.

Other Features Associated with the Third Invention Group

(1) While the active matrix type liquid crystal display of theembodiment 3-2 is arranged such that the pixel electrodes 271 and theswitching elements 243 are formed at substantially the same level on thesurface of the array substrate 206, an active matrix type liquid crystaldisplay having high aperture ratio may be employed in which the pixelelectrodes 271 are formed on a flattening film covering in a flatteningmanner the switching elements 243 or the wiring. More specifically, thisliquid crystal display has such a structure that the pixel electrodesare formed on the flattening film having a flattening function and theconductive particles are placed on the pixel electrodes, as described inthe description of the first invention group.

(2) Although the glass is employed as the material of the substrates inthe above embodiments, the substrates may be formed from plastics andeither of the substrates may be formed from a reflective material orformed from silicon.

(3) While polymer resin particles the surfaces of which are coated withan Au thin film, or Au spherical particles are used as the conductiveparticles in the above embodiments, other types of particles may beemployed, examples of which include metallic particles such as Ag, Niand Pd; polymer resin particles the surfaces of which are coated with aNi or ITO thin film; and inorganic material particles such as glass,aluminum oxides and titanium oxides. Further, zinc oxide whiskers havinga shape such as shown in FIG. 11 may be used as the conductiveparticles. The shape of the conductive particles is not particularlylimited.

(4) The diameter of the conductive particles should be smaller than thegap between the substrates when assembled. Where the conductiveparticles are placed on both of the substrates, the diameter of theconductive particles may be smaller than one half the gap between thesubstrates. With this arrangement, electrical contact between theelectrodes on the substrates can be avoided.

(5) As the particle diameter becomes larger, higher applied voltage isnecessary. The conductive particles may have a diameter greater thanabout one hundredth the gap between the substrates. The number ofconductive particles to be dispersedly placed may be at least one forevery pixel. Alternatively, a plurality of conductive particles may beplaced for every pixel.

Embodiments of the Fourth Invention Group

FIG. 12 diagrammatically, roughly shows the tendency of changes in themovement of the liquid crystal directors within the liquid crystal layerwhen voltage is applied to a typical OCB mode type liquid crystaldisplay, the voltage being sequentially increased in the way representedby 0→V1→V2→V3→V4→V5 (0<V1<V2<V3<V4<V5).

It should be noted that the same initial value is set for the liquidcrystal pretilt angles (i.e., liquid crystal pretilt angles at the timeof no voltage application) of both of the right and left alignment layerinterfaces (while the alignment layer interfaces are positioned on theright and left hands in FIG. 12, they are actually positioned on thefront and back sides when they are in service).

Referring to FIG. 12, the changes in the alignment will be described indetail.

FIG. 12(a) shows the alignment state (spray state) of a liquid crystalwhen no voltage is applied. In this case, a liquid crystal director 311a positioned at the center of the cell is reasonably horizontal withrespect to the substrates.

When a voltage V1 which is higher than a threshold is applied to theliquid crystal display in the condition of FIG. 12(a), the liquidcrystal molecule at the center of the cell first tilts as shown in FIG.12(b). Note that the liquid crystal molecule at the center of the cellis the most likely to move because it is far from the alignment layerswhich restrain the movement of the liquid crystal molecules. The abovetilting movement is accompanied with an increase in the liquid crystalpretilt angle at one alignment layer interface (on the left hand in FIG.12), while the liquid crystal pretilt angle at the other alignment layerinterface (on the right hand in FIG. 12) decreasing. At that time, theposition of the liquid crystal director 311 a which is horizontal to thesubstrates becomes closer to the alignment layer interface having alower pretilt angle.

FIGS. 12(c) and 12(d) illustrate conditions in which voltage is furtherapplied (voltage is increased). As shown in these figures, the pretiltangle in the higher pretilt alignment layer interface (on the left handin FIG. 12) further increases, whereas the pretilt angle in the lowerpretilt alignment layer interface (on the right hand in FIG. 12) furtherdecreases. In FIG. 12(d) which shows a condition where voltage isfurther increased, most of the liquid crystal molecules having directororientation horizontal to the substrates are present in close proximityto the lower pretilt alignment layer interface.

FIG. 12(e) shows an alignment state just before a transition to the bendalignment by application of voltage V4, and FIG. 12(f) shows analignment state when a transition to the bend alignment has beencompleted by application of voltage V5. While liquid crystal moleculeshaving director orientation parallel to the alignment layers are presentin FIG. 12(e), there is no such liquid crystal molecules in FIG. 12(f).

The liquid crystal display, which once has been brought into thealignment state shown in FIG. 12(f), is quickly shifted to the alignmentstate (steady state) shown in FIG. 12(g).

For quickly causing a spray to bend transition with the above transitionmechanism, the following conditions have been found to be important: theliquid crystal director orientation in the neighborhood of the center ofthe liquid crystal layer is perpendicular (orthogonal) to the alignmentlayers (substrates); and the pretilt angle in one alignment layerinterface is small. In other words, by meeting these conditions, a quickspray to bend transition can be achieved.

However, where a voltage in the level of several volts is applied, timeon the order of minutes is necessary for the initialization process asdiscussed earlier.

On the other hand, if a high voltage (e.g., 20V) is applied, anothercircuit becomes necessary, which disadvantageously leads to increasedliquid crystal display manufacturing cost, decreased reliability anddisplay abnormalities.

Therefore, this invention group is directed to an OCB mode liquidcrystal display which is characterized in that the alignment layerinterfaces, with which the liquid crystal molecules of the liquidcrystal layer sealed in the liquid crystal display are in contact, havean irregular configuration respectively for the purpose of causing aquick spray to bend transition.

The invention will be described below in accordance with itsembodiments.

Embodiment 4-1

FIG. 13 conceptually shows the sectional structure of a liquid crystaldisplay according to an embodiment 4-1 of the invention and, morespecifically, a test cell used in an experiment for checking the timetaken for a spray to bend transition.

The liquid crystal display of this embodiment was prepared by thefollowing manufacturing method: Firstly, Alignment Layer CoatingMaterial SE-7492 (including 6% solid components) produced by NissanChemical Industries, Ltd. was applied by letterpress printing onto twoglass substrates 301, 308 having transparent electrodes 302, 307, andthen cured in a thermostatic oven at a temperature of 180° C. for onehour, whereby alignment layers 306 were formed.

The letterpress printing plate used for the application of the alignmentlayers 306 was made from a general resin material and designed such thatthe number of screen lines=100 lines (2.54 mm/100 lines); mesh pointpitch=0.254 mm; 30% mesh point diameter=0.157 φ mm; mesh pointdepth=0.084 mm; mesh point angle=30 degrees. With this letterpressprinting plate, alignment layers having a thickness of about 0.1 μm and0.7 to 0.8 μm-high protrusions were formed.

The alignment layers 306 were rubbed with a rubbing cloth made of rayonand the substrates 301, 308 were adhered to each other by use of spacersproduced by Nippon Shokubai Co., Ltd. and Structbond XN-21-S (the nameof a sealing resin produced by Mitsui Toatsu Chemical Co., Ltd.) suchthat the gap between the substrates 301, 308 was 6.5 μm.

In this rubbing treatment, the same rubbing direction (as indicated byarrow of FIG. 13) was adapted for the substrates 301, 308.

Thereafter, Liquid Crystal MJ96435 produced by Merck & Co., Inc. wasvacuum-injected into the liquid crystal cell and the cell was sealed bySealing Resin 352A (the UV hardenable type resin produced by LoctiteJapan, Corp.).

Then, polarizers were attached to the substrates from above and belowsuch that the polarizing axes were at 45° with respect to the rubbingdirection of the alignment layers and such that the polarizing axescross each other at right angles, whereby a test cell was prepared. Thecell thus prepared is called “test cell A”.

For comparison, test cells R1 and R2 having the same structure as thetest cell A were produced in the same way as the test cell A, except thefollowing points: The alignment film material of the test cell R1 wasapplied by spin coating and the alignment film material of the test cellR2 was applied by use of a widely-used resinous letterpress printingplate having 300 screen lines.

Then, the time required for a transition from the spray alignment to thebend alignment throughout the electrode region was observed, when 45 Hz,7V rectangular waves were applied to each of the test cells A, R1 andR2.

TABLE 1 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells A, R1, R2 when 45 Hz, 7V rectangular waves wereapplied to these cells.

TABLE 1 TRANSITION TEST CELL TIME NOTES A −5 Molecules on the surfaceswere completely transited. R1 20-30 Molecules on the surfaces werecompletely transited. R2 20-30 Molecules on the surfaces were completelytransited (unit: sec.)

As seen from TABLE 1, the transition times of the test cells R1, R2 were20 to 30 sec., whereas the transition time of the test cell A of theinvention was quick, namely, no longer than 5 sec.

The above result is attributable to the following fact: The liquidcrystal molecules act so as to spuriously increase in their pretiltangle in regions where the thickness of the alignment layer changes.That is, asymmetry occurs in the spray alignment state by the amountcorresponding to the angle of inclination caused at the stepped portionsof the alignment layers. The synergistic effect of the asymmetry and theelectric field makes the liquid crystal directors more likely to beorthogonal to the test cell substrate surfaces and therefore to thealignment layer surfaces. Therefore, the displacement of the liquidcrystal directors proceeds extremely smoothly so that a high-speed sprayto bend transition can be carried out.

It is apparent from the comparison between the test cell R2 and the testcell A that if the number of screen lines in the resinous letterpressprinting plate increases, the effect of speeding up the transition willbe lost.

The reason for this is that as the number of screen lines in theresinous letterpress plate increases, stepped portions are more unlikelyto be created in the alignment layers, so that the coating filmcondition of this case becomes similar to that of the case where spincoating is adapted like the test cell R2 (i.e., the condition in whichno stepped portions exist).

TABLE 2 shows a change in the transition time of each test cell when 45Hz, 5V rectangular waves were applied in a similar voltage applicationtest.

TABLE 2 TRANSITION TEST CELL TIME NOTES A −40 Molecules on the surfaceswere completely transited. R1 420- There were remained non-transitedmolecules. R2 380- There were remained non-transited molecules. (unit:sec.)

As seen from TABLE 2, it took about 400 sec. for completing a transitionin the test cells R1 and R2. There were remained non-transited liquidcrystal molecules within this transition time and the transition wouldnot proceed further. In contrast to this, transition quickly occurredand finished in 40 sec. in the test cell A of the invention.

Embodiment 4-2

FIG. 14 conceptually shows the sectional structure of a liquid crystaldisplay constructed according to an embodiment 4-2 of the invention.

Except two points, the test cell used in the experiment for checking thespray to bend transition time of the liquid crystal display of theembodiment 4-2 is the same as that of the embodiment 4-1 in terms of theconfiguration and structure of mechanical parts; the method of producinga cell; used materials; and others. The first different point is thatelectrodes 310, 311 were formed so as to have an irregular configurationrespectively, using a UV asher, ozone asher or UV/ozone asher, andalignment layers 312, 313 were then formed on the electrodes 310, 311 sothat the alignment layers 312, 313 also have the irregular configurationrespectively. The second different point is that the formation of thealignment layers was done by spin coating. The test cell thus preparedis called “test cell B”.

As a comparative test cell, the foregoing test cell R1 was used. Thetime required for a transition from the spray alignment to the bendalignment throughout the electrode region was observed, when 45 Hz, 7Vrectangular waves were applied to each of the test cells B and R1.

TABLE 3 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells B, R1 when 45 Hz, 7V rectangular waves were applied tothese cells.

TABLE 3 TRANSITION TEST CELL TIME NOTES B −3 Molecules on the surfaceswere completely transited. R1 20-30 Molecules on the surfaces werecompletely transited. (unit: sec.)

As seen from TABLE 3, the transition time of the test cell R1 was 20 to30 sec., whereas the transition time of the test cell B of the inventionwas quick, namely, no longer than 3 sec.

This test result is attributable to the following fact: As shown in FIG.14, when the liquid crystal molecules within a liquid crystal layer 314are aligned on the surfaces of the alignment layers 312, 313 havingconfigurations which correspond to the irregular surface configurationsof the electrodes 310, 311 attached to the inner faces of thesubstrates, an alignment state having various liquid crystal directorsis taken as a spray state. As a result, marked asymmetry occurs in thespray alignment state, and by virtue of the synergistic effect of theasymmetry and the electric field, the liquid crystal directors becomelikely to be orthogonal to the substrate surfaces and thereforealignment layer surfaces of the test cell. Accordingly, the displacementof the liquid crystal directors proceeds extremely smoothly so that ahigh-speed spray to bend transition can be carried out.

Embodiment 4-3

Except two points, the test cell used in the experiment for checking thespray to bend transition time of the liquid crystal display of theembodiment 4-3 is the same as the test cell B in terms of theconfiguration and structure of mechanical parts; the method of producinga cell; used materials; and others. The first different point is that asshown in FIG. 15, the substrate used in the embodiment 4-3 is an arraysubstrate 316 having pixel electrodes and switching elements (notshown); flattening films 318, 317 are formed on the array substrate 316and an opposed substrate 315 having an opposed electrode (not shown)respectively; and the flattening films 318, 317 each have an irregularconfiguration. The second different point is that like the test cell R2,a resinous letterpress printing plate having 300 screen lines was used.

For forming the irregular configurations of the surfaces of theflattening films 317, 318, the aforesaid UV asher, ozone asher orUV/ozone asher was used. The cell thus prepared is called “test cell C”.

As a comparative test cell, the foregoing test cell R1 was used.

The time required for a transition from the spray alignment to the bendalignment throughout the electrode region was observed, when 45 Hz, 7Vrectangular waves were applied to each of the test cells C and R1.

TABLE 4 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells C, R1 when 45 Hz, 7V rectangular waves were applied tothese cells.

TABLE 4 TRANSITION TEST CELL TIME NOTES C −3 Molecules on the surfaceswere completely transited. R1 20-30 Molecules on the surfaces werecompletely transited. (unit: sec.)

As seen from TABLE 4, it took 20 to 30 sec. for the test cell R1 tofinish a transition, while a transition was quickly done in 3 sec. inthe test cell C.

Embodiment 4-4

Except two points, the test cell used in the experiment for checking thespray to bend transition time of the liquid crystal display of theembodiment 4-4 is the same as the test cell B in terms of theconfiguration and structure of mechanical parts; the method of producinga cell; used materials; and others. The first different point is thatthe used array substrate itself has an irregular configuration and aflattening film is formed on such a substrate. The second differentpoint is that like the test cell R2, a resinous letterpress printingplate having 300 screen lines was used.

For forming the irregular configurations of the surfaces of thesubstrates, the aforesaid UV asher, ozone asher or UV/ozone asher wasused. The cell thus prepared is called “test cell D”.

For comparison, the foregoing test cell R1 was used.

The time required for a transition from the spray alignment to the bendalignment throughout the electrode region was observed, when 45 Hz, 7Vrectangular waves were applied to each of the test cells C and R1.

TABLE 5 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells D, R1 when 45 Hz, 7V rectangular waves were applied tothese cells.

TABLE 5 TRANSITION TEST CELL TIME NOTES D −3 Molecules on the surfaceswere completely transited. R1 20-30 Molecules on the surfaces werecompletely transited. (unit: sec.)

As seen from TABLE 5, it took 20 to 30 sec. for transition in the testcell R1, while transition was quickly done in 3 sec. in the test cell Daccording to the invention.

Embodiment 4-5

Except one point, the test cell used in the experiment for checking thespray to bend transition time of the liquid crystal display of theembodiment 4-5 is the same as the test cell A in terms of theconfiguration and structure of mechanical parts; the method of producinga cell; used materials; and others. The different point is that thealignment layers were formed from an alignment film material in whichpowder, fine particles or the like were dispersed by printing or spincoating. More concretely, spacers were dispersed into the alignment filmmaterial in an amount of 3 wt % and a test cell was prepared by printingwith a resinous letterpress printing plate having 300 screen lines. Thecell thus prepared is called “test cell E”.

For comparison, the foregoing test cell R1 was used.

The time required for a transition from the spray alignment to the bendalignment throughout the electrode region was observed, when 45 Hz, 7Vrectangular waves were applied to each of the test cells E and R1.

TABLE 6 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells E, R1 when 45 Hz, 7V rectangular waves were applied tothese cells.

TABLE 6 TRANSITION TEST CELL TIME NOTES E −2 Molecules on the surfaceswere completely transited. R1 20-30 Molecules on the surfaces werecompletely transited. (unit: sec.)

As seen from TABLE R1, it took 20 to 30 sec. for the test cell R1 tofinish a transition, while a transition was quickly done in 3 sec. inthe test cell E of the invention.

This test result is attributable to the fact that as shown in FIG. 16,the liquid crystal molecules within the liquid crystal layer 314 arealigned along the surface of the scattered spacer 310 covered with thealignment layer, forming a region in which liquid crystal directors areperpendicular to the substrate 308. When applying an electric field tothis region, the liquid crystal directors become likely to beperpendicular to the test cell substrate surfaces and therefore thealignment layer surfaces, by virtue of the synergistic effect of theabove region serving as a core and the electric field. Accordingly, thedisplacement of the liquid crystal directors proceeds extremelysmoothly, so that a high-speed spray to bend transition can be carriedout.

It is apparent from the above description that the liquid crystaldisplays of this invention group enables high-speed, reliable spray tobend alignment transition without sacrificing the characteristics of theconventional OCB mode so that they have a wide range of practicalapplications.

Other Features Associated with the Fourth Invention Group

The fourth invention group has been described, but it is apparent thatthe invention is not limited to the above embodiments.

For instance, modifications may be made as follows:

(1) The invention may be applied not only to the OCB mode but also toliquid crystal displays of any other modes that require speeding up ofthe phase transition of the liquid crystal layer. The liquid crystaldisplays to which the invention is applied may be of any modeirrespective of the reflective type or transmissive type.

(2) In reflective type liquid crystal displays, the reflector itself hasa special pattern of an irregular configuration for increasing a viewingangle, whiting and improving reflection brightness etc. Where theinvention is applied to a reflective type liquid crystal display, theirregular configuration of the reflector may be utilized.

(3) The irregular configuration is not necessarily formed over theentire surface of each pixel, but may be present at part of the pixel.The bend state can develop from this part, expanding over the entiresurface of the pixel. Therefore, the irregular configuration may beformed by use of several masks during the preparation of TFT. Of course,the formation of such a partial irregular configuration can also becarried out in any other process than the TFT preparation process.

(4) Formation of the irregular configurations on the alignment layersurfaces may be carried out by other methods than the above-describedmethod in which the irregular configurations are formed by printing orspin coating, using an alignment film material including powder, fineparticles or the like dispersed therein. The same effect as that of theabove method can be achieved by the following process: spacers arescattered just after printing the alignment layers, and afterprovisional curing, the alignment film material is again coated. Inaddition, it is also possible to directly spray the alignment filmmaterial in which spacers are dispersed, using a wet-type applicator.

Embodiments of the Fifth Invention Group

The fifth invention group of the invention will be described below. Thisinvention group is characterized in that, with the intention of quickly,reliably carrying out the spray to bend transition in every pixel, theliquid crystal molecules encapsulated in an OCB mode liquid crystaldisplay have an “HAN alignment” at the adhering positions of spacerswhich an adhesive is applied to and the liquid crystal molecules are incontact with.

The invention will be hereinafter described according to itsembodiments.

Embodiment 5-1

FIG. 17 conceptually illustrates the sectional structure of a test cellof a liquid crystal display constructed according to an embodiment 5-1of the invention. Specifically, FIG. 17 shows a schematic sectional viewof a test cell used in an experiment for checking the time taken for aspray to bend transition.

There will be explained a method of manufacturing the liquid crystaldisplay of this embodiment. Firstly, Alignment Film Coating MaterialSE-7492 produced by Nissan Chemical Industries, Ltd. (solid components6%) was applied onto two glass substrates 401, 408 having transparentelectrodes 402, 407 respectively, by the spinner method and then curedin a thermostatic oven at a temperature of 180° C. for one hour, therebyforming alignment layers 403, 406.

Thereafter, the alignment layers 403, 406 were rubbed pixel by pixel,using a rubbing cloth made of rayon, and spacers 405 produced by NipponShokubai Co., Ltd. (2-3 μm Beads GPZ-60 coated with 25 wt % of anadhesive 410) were scattered on the glass substrate 408. Then, the cellwas placed horizontally within a thermostatic oven at 180° C. for 10minutes, thereby securely adhering the spacers 405 to the substrate 408.The adhesive 410 spread to the extent substantially equal to thediameter of the spacers 405.

The material of the adhesive 410 may have such a performance that allowsthe liquid crystal to be oriented in a vertical, high-tilt alignment onthe surface of the adhesive 410. For example, fluorine or the like isintroduced into the molecular structure of the adhesive 410 therebyenhancing the vertical alignment of the liquid crystal of the liquidcrystal layer. It is also possible to mix the adhesive with a fluorinetype alignment material, fluorine type material, or long chain alkyltype material.

Then, Structbond XN-21-S (the product name of a sealing resin producedby Mitsui Toatsu Chemical Co., Ltd.) was used as a sealing resin toadhere the glass substrates 401, 408 such that the gap between thesubstrates 401, 408 was 6.5 μm, whereby a liquid crystal cell wasprepared.

In the above process, the upper side of one substrate and the lower sideof the other substrate (see FIG. 17) were rubbed in the same directionas shown in FIG. 18.

Then, Liquid Crystal MJ96435 produced by Merck & Co., Inc. wasintroduced into the liquid crystal cell by vacuum injection and the cellwas sealed with Sealing Resin 352A (the UV-hardenable type resinproduced by Loctite Japan, Corp.).

Polarizers (not shown) were then attached to the substrates from aboveand below respectively such that the polarizing axes were at 45° withrespect to the rubbing direction of the alignment layers and such thatthe polarizing axes cross each other at right angles, whereby a testcell was prepared. The cell thus prepared is called “test cell A”.

For comparison, a test cell R having the same structure as the test cellof the embodiment 5-1 was produced in the same way as the embodiment5-1, except that GPZ-60 coated with no adhesive was used. This cell iscalled “test cell R”.

Then, the time required for a transition from the spray alignment to thebend alignment throughout the electrode region was observed, when 45 Hz,7V rectangular waves were applied to each of the test cells A and R.

TABLE 7 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells A, R when 45 Hz, 7V rectangular waves were applied tothese cells.

TABLE 7 TRANSITION TEST CELL TIME NOTES A −4 Bend transition coresdeveloped from spacer portions and transition was completed in aninstant. R 20-30 A few bend transition cores developed randomly andcomplete transition took time. (unit: sec.)

As seen from TABLE 7, the transition time of the test cell R was 20 to30 sec., whereas the transition time of the test cell A was quick, thatis, no longer than 4 sec.

The above result is attributable to the following fact: In the conditionshown in FIG. 17, the liquid crystal molecules spuriously increase intheir pretilt angle within the regions that are not the alignment layerregions but the adhesive regions. That is, the spurious one-side HANalignment causes asymmetry in the spray alignment state, and thesynergistic effect of the asymmetry and the electric field makes theliquid crystal directors more likely to be orthogonal to the test cellsubstrate surfaces and the alignment layer surfaces. Therefore, thedisplacement of the liquid crystal directors proceeds extremely smoothlyso that a high-speed spray to bend transition can be carried out.

TABLE 8 shows a change in the transition time of each cell when 45 Hz,5V rectangular waves were applied in the similar voltage applicationtest.

TABLE 8 TRANSITION TEST CELL TIME NOTES A −30 Bend transition coresdeveloped from spacer portions. Transition was completed but speed wasslow. R 420- The number of developed transition cores was extremelysmall. Non-transited portions were left. (unit: sec.)

As seen from TABLE 8, the transition time of the test cell R was about400 sec. Non-transited molecules were left within this transition timeand the transition would not proceed further. In contrast to this, atransition quickly occurred and finished in 30 sec. in the test cell A.

Embodiment 5-2

Except one point, the test cell used in the experiment for checking thespray to bend transition time of the liquid crystal display of theembodiment 5-2 is the same as that of the embodiment 5-1 in terms of theconfiguration and structure of mechanical parts; the method of producinga cell; used materials; and others. The different point is that the cellwas not horizontally but vertically placed in the thermostatic oven at180° C. for 10 minutes thereby securely attaching the spacers 405 to thesubstrate 408, so that, as shown in FIG. 19, an adhesive 411 spread fromeither side of each spacer 405 to the extent substantially equal to theradius of the spacer 405. The cell thus prepared is called “test cellB”.

For comparison, the test cell A of the embodiment 4-1 was used. The timerequired for a transition from the spray alignment to the bend alignmentthroughout the electrode region was observed, when 45 Hz, 7V rectangularwaves were applied to each of the test cells A and B.

TABLE 9 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells A, B when 45 Hz, 7V rectangular waves were applied tothese cells.

TABLE 9 TRANSITION TEST CELL TIME NOTES A −4 Molecules on the surfaceswere completely transited. B −4 Molecules on the surfaces werecompletely transited. (unit: sec.)

It is apparent from TABLE 9 that the transition time was within 4 sec.in both of the test cells A, B. The reason for this is that the area ofthe one-side HAN alignment when the cell is horizontally placed and theadhesive is spread uniformly with respect to the contact point betweeneach spacer and the substrate is substantially the same as that when thecell is vertically placed and the adhesive is spread non-uniformly withrespect to the same. Accordingly, a smooth spray to bend transition canbe carried out in this embodiment.

Embodiment 5-3

FIG. 20 conceptually illustrates the sectional structure of a test cellfor a liquid crystal display constructed according to an embodiment 5-3of the invention.

Except two points, the test cell used in the experiment for checking thespray to bend transition time of the liquid crystal display of theembodiment 5-3 is the same as the test cell A in terms of theconfiguration and structure of mechanical parts; the method of producinga cell; used material; and others. The first different point is thatspacers 415 having a diameter of 5 μm were used for gap formation aswell. The second different point is that the upper and lower substrates401, 408 were overlaid and the adhesive 410 was spread over the upperand lower substrates 401, 408 while the substrates 401, 408 beingbrought into contact with the spacers 415. The cell thus prepared iscalled “test cell C”.

For comparison, the test cell A of the embodiment 5-1 was used. The timerequired for a transition from the spray alignment to the bend alignmentthroughout the electrode region was observed, when 45 Hz, 7V rectangularwaves were applied to each of the test cells C and A.

TABLE 10 shows the time required for a transition from the sprayalignment to the bend alignment throughout the electrode region in eachof the test cells C, A when 45 Hz, 7V rectangular waves were applied tothese cells.

TABLE 10 TRANSITION TEST CELL TIME NOTES C −2 Molecules on the surfaceswere completely transited. A −4 Molecules on the surfaces werecompletely transited. (unit: sec.)

It is apparent from TABLE 10 that the transition time of the test cell Awas within 4 sec., whereas the transition time of the test cell C wasquicker, that is, no longer than 2 sec. The reason for this is thatwhile the embodiments 5-1 and 5-2 respectively had a spurious one-sideHAN alignment, a top/bottom HAN alignment occurred in the embodiment 5-3so that the spray to bend transition could be further speeded up.

Additionally, in the liquid crystal display of the embodiment 5-3, aspurious HAN alignment could be formed simultaneously with the formationof the gap between the substrates by the spacers, so that themanufacturing process could be simplified, leading to a low costprocess.

It will be understood from the above description that the liquid crystaldisplays of the fifth invention group enable high-speed, reliable sprayto bend alignment transition without sacrificing the characteristics ofthe conventional OCB mode, so that they have a wide range of practicalapplications.

Other Features Associated with the Fifth Invention Group

The fifth invention group of the invention has been described accordingto several embodiments, but it is apparent that the fifth inventiongroup is not limited to the above embodiments.

For instance, modifications may be made as follows:

(1) Although the spread of the adhesive is set to be approximately equalto the diameter of the spacers in the foregoing embodiments, it may besmaller than the diameter of the spacers or alternatively may exceed it.As the adhesive spreads more, the region of the HAN alignment is moreexpanded, so that the alignment transition can be more easily carriedout.

(2) The fifth invention group is applicable not only to the OCB mode butalso to liquid crystal displays of any modes that require speeding up ofthe phase transition of the liquid crystal layer. In addition, theliquid crystal displays to which this group is applicable may be of anymode irrespective of the reflective type or transmissive type.

(3) By weakening or eliminating part of the aligning function of thesubstrate surfaces which have undergone alignment treatment beforehand,the speeding up of the bend transition in the invention can be achieved.Accordingly, any techniques may be utilized as far as such anarrangement can be achieved.

(4) Where a liquid crystal display is made by use of substrates preparedby forming a column-like configuration on a resist by photolithography,a similar bend transition develops from the aggregate parts.Accordingly, the formed configuration itself may have a structure orarrangement that impairs rubbing.

Industrial Applicability

As has been described earlier, the object of the invention can besatisfactorily accomplished by the configurations proposed by theinvention.

Specifically, the invention provides a liquid crystal display whichcomprises a pair of substrates and a liquid crystal layer sandwichedbetween the pair of substrates; wherein where the alignment state of aliquid crystal when no voltage is applied to the crystal layer isdefined as an alignment state 1 and the alignment state of the liquidcrystal used for performing displaying is defined as an alignment state2, the alignment state 1 differs from the alignment state 2; and whereinthe interface between the liquid crystal layer and at least one of thepair of substrates is flattened, whereby a reliable, fast transition canbe carried out and display defects can be eliminated and whereby highresponse speed, a wide viewing angle and high picture quality can beachieved.

The invention also provides an active matrix type liquid crystal displaywherein a liquid crystal layer is sandwiched between an array substratehaving pixel electrodes and an opposed substrate having an opposedelectrode and displaying is performed by orienting the liquid crystallayer in a bend alignment; and wherein conductive formation memberselectrically conducted to the opposed electrode are formed on theopposed substrate, being electrically insulated from the arraysubstrate, so that a diagonal strong electric field is developed andapplied across the electrically conductive formation members and thepixel electrodes, causing an electric field distortion which makes thedistortion energy of the liquid crystal molecules within the liquidcrystal layer positioned in the vicinity of the electrically conductiveformation members and in the vicinity of the pixel electrodes higherthan the surroundings, so that, by applying high voltage across thepixel electrodes and the opposed electrode in the above condition,transition cores of the bend alignment can be developed and the regionsof the bend alignment can be expanded.

The invention also provides a liquid crystal display which comprises apair of substrates having electrodes and a liquid crystal layersandwiched between the pair of substrates; wherein liquid crystalmolecules within the liquid crystal layer are oriented in a bendalignment to perform displaying; and wherein at least one conductiveparticle having a diameter smaller than the space between the pair ofsubstrates is placed on the electrode surface of at least either one ofthe substrates, thereby causing electric field concentration in theconductive particle so that transition cores of the bend alignment canbe developed and the bend alignment regions can be expanded bycontinuous application of high voltage.

The invention provides another liquid crystal display which comprises apair of substrates having electrodes and a liquid crystal layersandwiched between the pair of substrates; wherein the liquid crystallayer is oriented in a spray alignment; and wherein the surfaces of thealignment layers formed on the surfaces of the electrodes respectivelyhave an irregular configuration so that the pretilt angle of liquidcrystal molecules within the liquid crystal layer spuriously increasesowing to regions which vary in alignment layer thickness and as aresult, a shift to the bend alignment can be quickly carried out duringinitialization of a spray to bend transition.

The invention further provides a liquid crystal display which comprisesa pair of substrates having electrodes and a spray-aligned liquidcrystal layer sandwiched between the pair of substrates, wherein aplurality of spacers are placed between the pair of substrates, whereinthe spacers are securely attached to at least one of the substrates withan adhesive which increases the pretilt angle of liquid crystalmolecules within the liquid crystal layer, and wherein the adhesive isspread over the substrate, so that the pretilt angle of the liquidcrystal molecules spuriously increases in every spacer region owing toregions where said at least one of the pair of substrates differs fromthe other substrate and as a result, a transition to the bend alignmentcan be quickly carried out during initialization of a spray to bendtransition.

What is claimed is:
 1. A liquid crystal display comprising: a firstsubstrate having a pixel electrode; a second substrate having an opposedelectrode; a liquid crystal layer sandwiched between the first substrateand the second substrate and transitioned from a splay alignment to abend alignment by applying a voltage between the pixel electrode and theopposed electrode; a first alignment layer provided between the firstsubstrate and the liquid crystal layer; and a second alignment layerprovided between the second substrate and the liquid crystal layer;wherein at least either of the first alignment layer or the secondalignment layer is an irregular alignment layer formed by letterpressprinting wherein a region of a surface of the irregular alignment layerabove the pixel electrode has an irregular configuration, the surface ofthe first alignment layer being on a side of the liquid crystal layer.2. A liquid crystal display comprising: a first substrate having a pixelelectrode; a second substrate having an opposed electrode; a liquidcrystal layer sandwiched between the first substrate and the secondsubstrate and transitioned from a splay alignment to a bend alignment byapplying a voltage between the pixel electrode and the opposedelectrode; a first alignment layer provided between the first substrateand the liquid crystal layer; and a second alignment layer providedbetween the second substrate and the liquid crystal layer; wherein (1)at least either of the first alignment layer or the second alignmentlayer is an irregular alignment layer wherein a region of a surfaceabove the pixel electrode has an irregular configuration, the surface ofthe first alignment layer being on a side of the liquid crystal layer;(2) an electrode on which the irregular alignment layer is provided isan irregular electrode wherein a surface of the irregular electrode on aside of the liquid crystal layer has an irregular configuration, theelectrode being either of the pixel electrode of the first substrate orthe opposed electrode of the second substrate; and (3) a pattern of theirregular configuration of the irregular alignment layer corresponds tothe irregular configuration of the irregular electrode.
 3. A method ofmanufacturing a liquid crystal comprising a first substrate having apixel electrode, a second substrate having an opposed electrode, aliquid crystal layer sandwiched between the first substrate and thesecond substrate and transitioned from a splay alignment to a bendalignment by applying a voltage between the pixel electrode and theopposed electrode, a first alignment layer provided between the firstsubstrate and the liquid crystal layer, and a second alignment layerprovided between the second substrate and the liquid crystal layer,wherein at least either of the first alignment layer or the secondalignment layer is an irregular alignment layer wherein a region of asurface of the irregular alignment layer above the pixel electrode hasan irregular configuration, the surface of the first alignment layerbeing on a side of the liquid crystal layer, the method comprising:forming an electrode irregular configuration on a surface of anelectrode on which the irregular alignment layer is to be provided, theelectrode being either of the pixel electrode of the first substrate orthe opposed electrode of the second substrate, by use of a UV usher,ozone usher, or UV/ozone usher; and forming the irregular alignmentlayer having the irregular configuration with a pattern corresponding toa pattern of the electrode irregular configuration by applying amaterial of the irregular alignment layer on the electrode having theelectrode irregular configuration.
 4. A method of manufacturing a liquidcrystal display comprising a first substrate having a pixel electrode, asecond substrate having an opposed electrode, a liquid crystal layersandwiched between the first substrate and the second substrate andtransitioned from a splay alignment to a bend alignment by applying avoltage between the pixel electrode an the opposed electrode, a firstalignment layer provided between the first substrate and the liquidcrystal layer, and a second alignment layer provided between the secondsubstrate and the liquid crystal layer, wherein at least either of thefirst alignment or the second alignment layer is an irregular alignmentlayer wherein a region of a surface of the irregular alignment layerabove the pixel electrode has an irregular configuration, the surface ofthe first alignment layer being on a side of the liquid crystal layer,the method comprising: adjusting a material of the irregular alignmentlayer by dispersing powder or fine particles into a printing varnish;and forming the irregular alignment layer having the irregularconfiguration corresponding to a disposition of the powder or the fineparticles by applying the material of the irregular alignment on asurface of either of the pixel electrode or the opposed electrode.
 5. Aliquid crystal display comprising: a first substrate having a pixelelectrode; a second substrate having an opposed electrode; a liquidcrystal layer sandwiched between the first substrate and the secondsubstrate and transitioned from a splay alignment to a bend alignment byapplying a voltage between the pixel electrode and the opposedelectrode; a first alignment layer provided between the first substrateand the liquid crystal; and a second alignment layer provided betweenthe second substrate and the liquid crystal layer; wherein (1) at leasteither of the first alignment layer or the second alignment layer is anirregular alignment layer wherein a region of a surface of the irregularalignment layer above the pixel electrode has an irregularconfiguration, the surface of the first alignment layer being on a sideof the liquid crystal layer; and (2) in the irregular configuration ofthe irregular alignment layer, a largest level difference between ahighest portion and a lowest portion is larger than a smallest thicknessof the irregular alignment layer but smaller than an average thicknessof the liquid crystal layer.
 6. A liquid crystal display according toclaim 5, wherein the largest level difference is larger than 0.1 μm butsmaller than 0.7 μm.
 7. A liquid crystal display comprising: a firstsubstrate having a pixel electrode; a second substrate having an opposedelectrode; a liquid crystal layer sandwiched between the first substrateand the second substrate and transitioned from a splay alignment to abend alignment by applying a voltage between the pixel electrode and theopposed electrode; a first alignment layer provided between the firstsubstrate and the liquid crystal layer; and a second alignment layerprovided between the second substrate and the liquid crystal; wherein(1) at least either of the first alignment layer or the second alignmentlayer is an irregular alignment layer wherein a region of a surface ofthe irregular alignment layer above the pixel electrode has an irregularconfiguration, the surface of the first alignment layer being on a sideof the liquid crystal layer; and (2) at least either of the firstalignment or the second alignment layer comprises powder or fineparticles, and a pattern of the irregular configuration corresponds to adisposition of the powder or the fine particles.